Polymeric Component

ABSTRACT

An elastomeric material molded into a crease pattern is described. Also described are processes for making an elastomeric material having a crease pattern as well as useful items made from the elastomeric material having a crease pattern.

BACKGROUND OF THE INVENTION

The prototypical crease pattern object is generally referred to as origami. Typically, an origami is made from paper folded in certain ways. While pleasing to look at, an origami generally lacks strength.

Non-paper materials have been formed in crease patterns. For instance, solar panels for a space craft were assembled in a crease pattern so that they could be shipped into space in a folded conformation, and readily unfolded into a size that would have been too large for the space craft to carry. In this instance, a rigid material was formed into the crease pattern.

U.S. Pat. No. 7,521,292 to Rodgers describes a crease pattern made from elastomers. The crease patterns of this patent are described as flexible, however, the crease pattern of the objects described are very small. For instance, the patent refers to “a sine wave conformation with periodicities between about 500 nanometers and 100 microns, and preferably for some applications periodicities between about 5 microns to about 50 microns.”

BRIEF SUMMARY OF THE INVENTION

A first embodiment of the present invention provides a polymeric component having a component wall thickness of between about 0.1 and 20 mm; a Shore durometer A scale value between about 15 and 85; and a repeating crease pattern. It is preferred that the component wall thickness is between about 0.5 and 10 mm.

A second embodiment of the present invention provides process for making a polymeric component wherein a solution of a polymeric reaction mixture is prepared; said polymeric reaction mixture is injected into a mold, said mold having a crease pattern shape; said polymeric reaction mixture is set/cured and then removed from said mold. In a preferred embodiment of the process for making the polymeric component, the setting reaction is carried out for between about 0.17 to 18 hours at a temperature of between about 55 and 80° F. In an alternative preferred embodiment of the process for making the polymeric component, the setting reaction is carried out for between about 5 and 30 minutes at a temperature of between about 190 and 440° F. In a further preferred embodiment, the setting reaction is carried out under conditions that reduce the air dissolved in the polymeric reaction mixture so as to provide a substantially air bubble free component, for instance by pressurizing the mold with the injected polymeric reaction mixture to a pressure of between about 200 and 2300 psig.

In further embodiments of the present invention, the polymeric component is incorporated into a floor mat; a container; a body part protector, or a tarp.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING

FIG. 1 is a side perspective view of an edge pattern of an embodiment of the polymeric composition of the present invention.

FIG. 2 is a top perspective view of a second embodiment of the polymeric composition of the present invention.

FIG. 3 is a side elevation view of a third embodiment of the polymeric composition of the present invention.

FIG. 4 is a side elevation view of an open mold used to make an embodiment of the polymeric composition of the present invention.

FIG. 5 is a side elevation view of a fourth embodiment of the polymeric composition of the present invention.

FIG. 6 is a top elevation view of a fifth embodiment of the polymeric composition of the present invention.

FIG. 7 is a side elevation view of another open mold used to make an embodiment of the polymeric composition of the present invention.

FIG. 8 is a side elevation view of a further open mold used to make an embodiment of the polymeric composition of the present invention.

FIG. 9 is another view of the open mold of FIG. 8 used to make an embodiment of the polymeric composition of the present invention.

FIG. 10 is a side elevation view of a sixth embodiment of the polymeric composition of the present invention.

FIG. 11 is a side elevation view of a seventh embodiment of the polymeric composition of the present invention.

FIG. 12 is a side elevation view of an eighth embodiment of the polymeric composition of the present invention.

FIG. 13 is a side elevation view of a ninth embodiment of the polymeric composition of the present invention.

FIG. 14 is a side elevation view of a tenth embodiment of the polymeric composition of the present invention.

FIG. 15 is a side elevation view of an eleventh embodiment of the polymeric composition of the present invention.

FIG. 16 is a side view of a body part protector on a user's arm, the body protector made, in part, from an embodiment of the polymeric composition of the present invention.

FIG. 17 is a cut open side view of a body part protector on a user's arm, the body protector made, in part, from an embodiment of the polymeric composition of the present invention.

FIG. 18 is a side view of a body part protector that is not on a user, the body protector made, in part, from an embodiment of the polymeric composition of the present invention.

FIG. 19 is a view of a reaction mixture being injected into a mold in the process of making a polymeric composition of the present invention.

FIG. 20 is a view of a pressure vessel containing a mold into which the reaction mixture was injected in the process of making a polymeric composition of the present invention.

FIG. 21 is a view of a container made from embodiments of the polymeric composition of the present invention in which a laptop computer is partial in the container.

FIG. 22 is a view of a container made from embodiments of the polymeric composition of the present invention shown in FIG. 21 in which a laptop computer completely out of the container.

FIG. 23 is a view of tarp embodiment of the present invention suspended by a pair of ropes.

FIG. 24 is a view of a wall hanging having a plurality of tile embodiments.

FIG. 25 is a view of an alternative wall hanging having a plurality of tile embodiments.

DETAILED DESCRIPTION OF THE INVENTION

Referring to the drawings, like numerals indicate like elements and the same number appearing in more than one drawing refers to the same element. In addition, hereinafter, the following definitions apply:

The “wavelength” (or periodicity) of a crease pattern is the spatial period of the wave—the distance over which the wave's shape repeats—i.e., crest to crest or trough to trough.

“Component wall thickness” refers to the dimensions of a cross section of a wave of the crease pattern. Component wall thickness dimensions include width, thickness, radius, and diameter. For example, a polymeric component of the present invention having a ribbon shape is characterized by a length and two cross sectional dimensions: thickness and width.

“Substantially longitudinally oriented” refers to an orientation such that the longitudinal axes of a polymeric component of the present invention, are oriented substantially parallel to a selected alignment axis. In the context of this definition, substantially parallel to a selected axis refers to an orientation within 10 degrees of an absolutely parallel orientation, more preferably within 5 degrees of an absolutely parallel orientation.

“Stretchable” refers to the ability of a material, structure, device or device component to be strained without undergoing fracture. In an exemplary embodiment, a stretchable material, structure, device or device component may undergo strain larger than about 0.5% without fracturing, preferably for some applications strain larger than about 1% without fracturing and more preferably for some applications strain larger than about 3% without fracturing. In some embodiments of the present invention, the material of the present invention can be stretched more than 300% in any direction. However, at present, no embodiment of the present invention has been able to be stretched by more than about 450% in a single direction.

The terms “flexible” and “bendable” are used synonymously in the present description and refer to the ability of a material, structure, device or device component to be deformed into a curved shape without undergoing a transformation that introduces significant strain, such as strain characterizing the failure point of a material, structure, device or device component. In an exemplary embodiment, a flexible material, structure, device or device component may be deformed into a curved shape without introducing strain larger than or equal to about 5%, preferably for some applications larger than or equal to about 1%, and more preferably for some applications larger than or equal to about 0.5%.

“Plastic” refers to any synthetic or naturally occurring material or combination of materials that can be molded or shaped, generally when heated, and hardened into a desired shape. Exemplary plastics useful in the devices and methods of the present invention include, but are not limited to, polymers, resins and cellulose derivatives. In the present description, the term plastic is intended to include composite plastic materials comprising one or more plastics with one or more additives, such as structural enhancers, fillers, fibers, plasticizers, stabilizers or additives which may provide desired chemical or physical properties.

“Polymer” refers to a molecule comprising a plurality of repeating chemical groups, typically referred to as monomers. Polymers are often characterized by high molecular masses. Polymers useable in the present invention may be organic polymers or inorganic polymers and may be in amorphous, semi-amorphous, crystalline or partially crystalline states. Polymers may comprise monomers having the same chemical composition or may comprise a plurality of monomers having different chemical compositions, such as a copolymer. Cross linked polymers having linked monomer chains are particularly useful for some applications of the present invention. Polymers useable in the methods, devices and device components of the present invention include, but are not limited to, plastics, elastomers, thermoplastic elastomers, elastoplastics, thermostats, thermoplastics and acrylates. Exemplary polymers include, but are not limited to, acetal polymers, biodegradable polymers, cellulosic polymers, fluoropolymers, nylons, polyacrylonitrile polymers, polyamide-imide polymers, polyimides, polyarylates, polybenzimidazole, polybutylene, polycarbonate, polyesters, polyetherimide, polyethylene, polyethylene copolymers and modified polyethylenes, polyketones, poly(methyl methacrylate, polymethylpentene, polyphenylene oxides and polyphenylene sulfides, polyphthalamide, polypropylene, polyurethanes, styrenic resins, sulphone based resins, vinyl-based resins or any combinations of these.

“Elastomer” refers to a polymeric material which can be stretched or deformed and return to its original shape without substantial permanent deformation. Elastomers commonly undergo substantially elastic deformations. Exemplary elastomers useful in the present invention may comprise, polymers, copolymers, composite materials or mixtures of polymers and copolymers. Elastomers useful in the present invention may include, but are not limited to, thermoplastic elastomers, styrenic materials, olefinic materials, polyolefin, polyurethane thermoplastic elastomers, polyamides, synthetic rubbers, PDMS, polybutadiene, polyisobutylene, poly(styrene-butadiene-styrene), polyurethanes, polychloroprene and silicones.

Durometer is a standard measure of the hardness of a material. The durometer measurements reported herein a based on the Shore A scale: ASTM D2240 15-8. It is preferred that the polymeric material of the present invention has a Durometer Shore A value between about 15 and about 85. It is further preferred that the polymeric material of the present invention has a Durometer Shore A value between about 30 and about 70.

In the following description, numerous specific details of the devices, device components and methods of the present invention are set forth in order to provide a thorough explanation of the precise nature of the invention. It will be apparent, however, to those of skill in the art that the invention can be practiced without these specific details.

Polymeric composition 100 as shown in FIGS. 1, 2, 3, 5, 6, 10, 11, 12, 13, 14, and 15 demonstrate the range of the crease patterns that can be obtained using the present invention. For instance, the crest of the waves of polymeric composition 100 shown in FIG. 1 is very “sharp.” In contrast, the crest of the waves of polymeric composition 100 shown in FIG. 6 is flat. Depending upon the mold used in forming the polymeric composition 100 of the present invention, the crest may be sharp as shown in FIG. 1, flat as shown in FIG. 6, or of some intermediate curvilinear shape.

Furthermore, while the embodiments of polymeric composition 100 shown in the several FIGs. are substantially uniform—there is little discernable variation from one “wave” of polymeric composition 100 to the next—substantial uniformity is not necessary. Rather, the uniformity of the waves of a polymeric composition 100 of the present invention reflects the mold in which the composition is formed.

Thus, the wave pattern of polymeric composition 100 incorporated into body part protector 1800 shown in FIG. 18 varies across body part protector 1800. Specifically, the crest to crest distance between the waves of the polymeric composition 100 in body part protector 1800 is smaller in regions 1810 and 1820 that it is in region 1830.

Suitable polymers for blending or mixing with olefin block copolymer, especially ethylene based block interpolymers used in the present invention include, but are not limited to, another olefin block copolymer, especially ethylene based block interpolymers, low density polyethylene, heterogeneously branched LLDPE, heterogeneously branched ULDPE, medium density polyethylene, high density polyethylene, grafted polyethylene (e.g. a maleic anhydride extrusion grafted heterogeneously branched linear low polyethylene or a maleic anhydride extrusion grafted (MAH-g) homogeneously branched ultra low density polyethylene), ethylene acrylic acid copolymer, ethylene vinyl acetate copolymer, ethylene ethyl acrylate copolymer, polystyrene, polypropylene, polyester, polyurethane, polybutylene, polyamide, polycarbonate, rubbers, ethylene propylene polymers, ethylene styrene polymers, styrene block copolymers, and vulcanates.

It is preferred that the polymeric material of the present invention consist of polyurethane resins, silicone rubbers or polyvinyl chloride.

A number of different polymers may be used as the base component of adhesives in accordance with embodiments of the present invention, such as the olefin block copolymers, especially ethylene based block interpolymers. For example, ethylene vinyl acetate (EVA) based polymers may be used. The type and amount of wax and resin used with the EVA copolymer can control the set time and the residual tack of the adhesive. In some instances, filler may be added to EVA adhesives for special applications. Other embodiments of the present invention may use polyethylene-based polymers, polypropylene-based polymers, propylene-ethylene copolymers, amorphous poly alpha-olefins, polyamides, block copolymers, and/or other polymers known in the art. For example, ethylene ethyl acrylate (EEA), styrene-isoprene-styrene copolymers, styrene-butadiene-styrene copolymers, as well as a number of other styrene copolymers (SEBS, SEPS, etc.), polyurethane polyvinyl chloride, latex nitrile, acrylonitrile copolymers, acrylics (including pure acrylics as well as styrene acrylics and vinyl acrylics), and polyisobutylene may be used. In addition, polymers such as ethylene butyl acrylate (EnBA) and epoxydized polybutadiene (PBE) may be used. In preferred embodiments, synthetic polymers are used with embodiments of the present invention.

Again, this non-comprehensive list is just representative of the types of polymers that may be used in forming the dispersions and adhesive compositions in accordance with embodiments of the present invention. Those having ordinary skill in the art will recognize that a number of other suitable polymers exist.

Additionally, biocides that enhance biological stability may be used. Those having ordinary skill in the art will recognize that a number of suitable compounds exist. For example, chlorine, quaternary ammonium compounds, nano-particulate silver and sodium pentachlorophenate are all suitable examples. One particularly useful biocide is sold under the trademark DOWICIL 200, by The Dow Chemical Company (Midland, Mich.). Biocides may be present in a range from about 0 to about 1 weight percent of the total weight.

As used herein, the term “stretchable” refers to materials, structures, devices and device components capable of withstanding strain without fracturing or mechanical failure. Stretchable polymeric materials of the present invention preferred for some applications are flexible, in addition to being stretchable, and thus are capable of significant elongation, flexing, bending or other deformation along one or more axes.

Even when undergoing significant strain, such as strain greater or equal about 0.5%, preferably 1% and more preferably 2%. Stretchable polymeric materials of the present invention are flexible, bent and/or in a deformed states.

Exemplary polymeric materials of the present invention having curved internal surfaces useful in present invention comprise bent structures. In the context of this description, a “bent structure” refers to a structure having a curved conformation resulting from the application of a force. Bent structures in the present invention may have one or more folded regions, convex regions and/or concave regions. Bent structures useful in the present invention, for example, may be provided in a coiled conformation, a wrinkled conformation, a buckled conformation and/or a wavy (i.e., wave-shaped) configuration.

A flexible polymeric material of the present invention may be in a conformation wherein the bent structure is under strain. In some embodiments, the bent structure, such as a bent ribbon structure, is under a strain equal to or less than about 30%, a strain equal to or less than about 10% in embodiments preferred for some applications, a strain equal to or less than about 5% in embodiments preferred for some applications and a strain equal to or less than about 1% in embodiments preferred for some applications. In some embodiments, the bent structure, such as a bent ribbon structure, is under a strain selected from the range of about 0.5% to about 30%, preferably for some applications a strain selected from the range of about 0.5% to about 10%, preferably for some applications a strain selected from the range of about 0.5% to about 5%.

Surfaces of a flexible polymeric material of the present invention and, are provided in a bent structure, for example a bent structure having a coiled, wave-shaped, buckled and/or wrinkled conformation. The present invention includes embodiments wherein stretchable polymeric materials of the present invention are interconnected. Any conventional means of connecting polymeric materials may be used. For example, metal connectors (such as rivets, and nuts and bolts); leather (laces), sewing (thread) and adhesive connectors may be used.

The polymeric material of the present invention may have a coiled, wave-shaped, buckled and/or wrinkled configuration. In these embodiments, the bent structure enables these devices to exhibit good performance even when undergoing significant strain,

Bent structures and curved internal surfaces of polymeric material of the present invention may have any contour profile providing stretchability and/or flexibility including, but not limited to, contour profiles characterized by at least one convex region, at least one concave region or a combination of at least one convex region and at least one concave region. Contour profiles useful in the present invention include contour profiles varying in one or two spatial dimensions. Use of a bent structure having an internal surface with a contour profile exhibiting periodic or aperiodic variations in more than one spatial dimension are useful for providing stretchable crease pattern materials capable of stretching, compression, flexing or otherwise deformation in more than one direction, including orthogonal directions.

Useful embodiments include curved internal surfaces provided by bent polymeric material of the present invention having conformations comprising a plurality of convex and concave regions, for example an alternating pattern of convex and concave regions provided in a wave-shaped configuration. In an embodiment, the curved internal surface, or optionally the entire cross sectional component, of a stretchable and/or flexible polymeric material of the present invention has a contour profile characterized by a substantially periodic wave or, alternatively, a substantially aperiodic wave. In the context of this description, periodic waves may comprise any two or three dimensional wave form including but not limited to, one or more sine waves, square waves, Aries functions, Gaussian wave forms, Lorentzian wave forms, or any combination of these. In another embodiment, the curved internal surface, or optionally the entire cross sectional component, of a polymeric material of the present invention has a contour profile comprising a plurality of aperiodic buckles having relatively large amplitudes and widths. In another embodiment, the curved internal surface, or optionally the entire cross section component, of a polymeric material of the present invention has a contour profile comprising both a periodic wave and a plurality of aperiodic buckles.

In one embodiment, a stretchable polymeric material of the present invention comprises a bent structure, such as a bent ribbon structure, having a periodic or aperiodic wave-shaped conformation extending along at least a portion of its length, and optionally width. The invention includes, for example, bent structures, including bent ribbon structures, having a sine wave conformation with periodicities between about 200 microns to about 10 cm, and preferably for some applications periodicities between about 500 microns to about 2 cm. The invention includes, for example, bent structures, including bent ribbon structures, having a sine wave conformation with amplitudes between about 0.1 and about 20 mm and preferably for some applications amplitudes between about 0.5 and about 10 mm. Bent structures may be provided in other periodic wave form conformations such as square wave and/or Gaussian waves, extending along at least a portion of the lengths and/or widths of these structures. Stretchable and flexible polymeric material of the present invention comprising bent ribbon structures may be expandable, compressible, bendable and/or deformable along an axis extending along the length of the ribbon, such as an axis extending along the direction of a first wave form of the curved internal surface, and, optionally, may be expandable, compressible, bendable and/or deformable along one or more other axes, such as axes extending along the directions of other wave forms of the bent structures and curved internal surface.

In some embodiments, the conformation of crease pattern structures and electronic devices of this aspect of the present invention changes when mechanically stressed or when forces are applied. For example, the periodicities and/or amplitudes of bent crease pattern structures that have wave-shaped or buckled conformations may change in response to applied mechanical stress and/or forces. In some embodiments, this ability to change conformation provides for the ability of stretchable crease pattern structures to expand, compress, flex, deform and/or bend without experiencing significant mechanical damage, fracture.

In some embodiments, the wave-shaped, buckled and/or stretchable conformation provides a way to mechanically tune useful the properties of compositions, materials and devices of the present invention. For example, the mobility of a crease pattern structure, depend, at least in part, on strain. Spatially varying strain in the present invention is useful for modulating the materials and device properties in useful ways. As another example, spatially varying strain in a waveguide causes spatially varying index properties (through the elasto-optic effect), which can also be used to advantage for different types of grating couplers.

The physical dimensions and composition of the crease pattern structure at least in part influences the overall mechanical of the stretchable crease pattern elements of the present invention. Useful flexible substrates included, but are not limited to, flexible substrates having a component wall thickness selected over the range of about 0.1 millimeter to about 100 microns. In a useful embodiment, the flexible substrate comprises a poly(dimethylsiloxane) PDMS layer and has a component wall thickness selected over the range of about 0.1 millimeters to about 10 millimeters, preferably for some applications a component wall thickness selected over the range of about 1 millimeters to about 5 millimeters.

The composition and physical dimension of the supporting flexible substrate may also influence, at least in part, the overall mechanical properties of stretchable crease pattern structure of the present invention.

In some embodiments of this aspect of the invention, the prestrained elastic substrate is expanded along a first axis, and optionally along a second axis orthogonally positioned relative to the first axis.

To get better anti-reflection result, we can do further processing on this wavy surface, such as make surface roughness much smaller than wavelength of wavy crease pattern structure, for example. In short, the partially- or fully-processed wavy/bent crease pattern structures can be transferred onto other substrate (not limited to Polydimethylsiloxane (“PDMS”), and can be used with more enhanced performance, by adding further processing if necessary.

In one embodiment, a prepolymer, such as a PDMS pre-polymer, is cast and cured on the stretchable crease pattern structure. Such a polymer (e.g. 2D ultrathin polymer) or an inorganic (e.g. SiO₂) is a preferred embodiment.

The prepolymer, or polymer reaction mixture, is put into a mold 400 for the curing process. Typically, mold 400 is a two part mold having a first part 410, that when mold 400 is assembled, projects into second mold part 420. FIGS. 4, 7, 8, and 9 show examples of molds 400 in an open state with first mold parts 410 and second mold parts 420 lying next to each other. When assembled, molds 400 have a space between mold parts 410 and 420 that is in a crease pattern.

FIG. 19 illustrates the process of filling an assembled mold 400. Again, assembled mold 400 is formed from two parts, 410 and 420 respectively. Mold 400 has a plurality of openings 1930 that provide access to the space between the two mold parts 410 and 420. In FIG. 19, a reaction mixture inside the barrel of syringe 1910 is being injected into mold 400 in response to the pressure applied via plunger 1920. While syringe barrel 1910 may block access to the opening 1930 in which it is positioned, any gases inside mold 400 escape via the other openings 1930 as the reaction mixture is injected into mold 400.

After mold 400 has been injected with a volume of reaction mixture sufficient to substantially fill mold 400, mold 400 is placed upright in a pressure vessel. FIG. 20 shows pressure vessel 2000 which contains a mold 400 filled with a reaction mixture.

Methods of prestraining elastic substrates useful for the present methods include bending, rolling, flexing, and expanding the elastic substrate prior to and/or during contact and bonding with the crease pattern structure, for example by using a mechanical stage. A particularly useful means of prestraining the elastic substrates in more than one direction comprises thermally expanding the elastic substrate by raising the temperature of the elastic substrate prior and/or during contact and bonding with the crease pattern structure. Relaxation of the elastic substrate is achieved in these embodiments by lowering the temperature of the elastic substrate after contact and/or bonding with the transferable, and optionally printable, printable crease pattern structure. In some methods, the elastic substrate is prestrained by introducing a strain of about 1% to about 30%, and preferably for some applications by introducing a strain of about 3% to about 15%.

In the context of this description, the expression “elastic substrate” refers to a substrate (or structure) which can be stretched or deformed and return, at least partially, to its original shape without substantial permanent deformation. Elastic substrates commonly undergo substantially elastic deformations. Exemplary elastic substrates useful in the present include, but are not limited to, elastomers and composite materials or mixtures of elastomers, and polymers and copolymers exhibiting elasticity. In some methods, the elastic substrate is prestrained via a mechanism providing for expansion of the elastic substrate along one or more principle axes. For example, prestraining may be provided by expanding the elastic substrate along a first axes. The present invention also includes, however, methods wherein the elastic substrate is expanded along a plurality of axes, for example via expansion along first and second axis orthogonally positioned relative to each other. Means of prestraining elastic substrates via mechanisms providing expansion of the elastic substrate useful for the present methods include bending, rolling, flexing, flattening, expanding or otherwise deforming the elastic substrate. The present invention also includes means wherein prestraining is provided by raising the temperature of the elastic substrate, thereby providing for thermal expansion of the elastic substrate.

Example 1

A water clear, 65 Shore A polyurethane elastomer polymerization reaction mixture was prepared by blending substantially equal volumes of BJB Enterprises WC-565 Parts A and B at ambient temperature.

The label on the BJB Enterprises WC-565 Part A package identifies its components as:

Chemical Name Wt % CAS Number Poly [oxy(methyl-1,2-ethanediyl)], α- 60-70 9042-82-4 hydro-ω-hydroxy-, polymer with 1,1′- methylene-bis-[4, isocyanato cyclohexane] Dicyclohexylmethane-4,4′-diisocynate 30-40 5124-30-1 Propanoic acid, 2-methyl-,2,2- 1-5 6846-50-0 dimethyl-1-(1-methylethyl)-1,3- propanediyl ester Solvent naphtha, petroleum, light 1-2 64742-95-6 aromatic Xylene 0.9 1330-20-7 Ethylbenzene 0.3 100-41-1 Toluene <0.01 108-88-3

The label on the BJB Enterprises WC-565 Part B package identifies its components as:

Chemical Name Wt % CAS Number Polyether polyol mixture 95-100 Proprietary Phenyl mercuric neodecanoate (35% 0.37 26545-49-3 as Hg)

About 300 oz of the above Example 1 combined reaction mixture was injected into a crease pattern mold, at about 70° F. The exterior of the mold was about 10 inches long, about 8 inches wide and about 1 inch high. The mold with the injected reaction mixture was placed in a pressurized container at a pressure between about 70 and 80 psig of air for about 18 hours. Thereafter, the material was removed from the mold.

Example 2

A high tear strength, 60 Shore A polyurethane elastomer polymerization reaction mixture was prepared by blending about 100 parts, by volume of BJB Enterprises ST-1060 Part A with about 58 parts by volume of BJB Enterprises ST-1060 Part B at ambient temperature.

The label on the BJB Enterprises ST-1060 Part A package identifies its components as:

ST-1060 Part A Chemical Name Wt % CAS Number Polypropylene glycol polymer 1,3 >99.9 9057-91-4 diisocanatomethylbenzene terminated Toluene Diisocynate <0.1 26471-62-5

The label on the BJB Enterprises ST-1060 Part B package identifies its components as:

Chemical Name Wt % CAS Number Polyether polyol mixture 85-95 Proprietary Di-(methylthio)touenediamine  5-15 106264-79-3 Phenyl mercuric neodecanoate 0.39 26545-49-3 (35% as Hg)

About 300 oz of the above Example 2 combined reaction mixture was injected into a crease pattern mold, at 70° F. The exterior of the mold was about 10 inches long, about 8 inches wide and about 1 inch high. The mold with the injected reaction mixture was placed in a pressurized container at a pressure between about 70 and 80 psig of air for about 18 hours. Thereafter, the material was removed from the mold.

Example 3

A translucent silicone rubber polymerization reaction mixture was prepared by blending about 100 parts, by weight of BJB Enterprises TC-5040 Part A with about 10 parts by weight of BJB Enterprises TC-5040 Part B at ambient temperature.

The label on the BJB Enterprises TC-5040 Part A package identifies its components as:

Chemical Name Wt % CAS Number Siloxanes and Silicones, de-Me, vinyl <80 68083-19-2 group terminated Polydimethylsiloxane, Silica Adduct <20 67762-90-7 Platinum, dicarbonyldichloro-, reaction >1 73018-55-0 products with 2,4,6- trimethylcyclotrisiloxane

The label on the BJB Enterprises TC-5040 Part B package identifies its components as:

Chemical Name Wt % CAS Number Polydimethyl siloxane mixture >90 63148-60-7/ 471-34-1 Methyl Hydrogen Polysiloxane <10 68037-59-2

About 300 oz of the above Example 3 combined reaction mixture was injected into a crease pattern mold, at 70° F. The exterior of the mold was about 10 inches long, about 8 inches wide and about 1 inch high. The mold with the injected reaction mixture was placed in a pressurized container at a pressure between about 70 and 80 psig of air for about 18 hours. Thereafter, the material was removed from the mold.

FIGS. 16, 17, and 18 show a body part protector 1800 made using a polymeric composition 100 of the present invention. In this embodiment of a body part protector 1800, a piece of polymeric composition 100 is adhered to an elastic material 1840. Elastic material 1840 holds the polymeric composition 100 in place adjacent to the body part to be protected.

As shown in the cut-away view of FIG. 17, in some embodiments of the body protector 1800 of the present material, there is a backing layer 1860 behind polymeric composition 100. Again, elastic material 1840 is adhered to the periphery of polymeric composition 100 to hold the body part protector 1800 in its desired place.

The body part protector 1800 of the present invention provides protection to a body part by adsorbing energy—e.g., a blow—applied to the body part protected. The crease pattern polymeric composition 100 temporarily deforms and thereby adsorbs the applied energy.

FIGS. 21 and 22 illustrate an expandable container 2100 made from the polymeric composition 100 of the present invention. As shown in FIG. 21, expandable container 2100 is able to expand and envelope laptop computer 2110. However, as shown in FIG. 22, when the laptop computer 2110 is removed from container 2100, container 2100 contracts and in its contracted state, expandable container 2100 is smaller than laptop computer 2110.

In the embodiment of an expandable container 2100 shown in FIG. 21, two pieces of a polymeric composition 100 according to the present invention having about the same length and width are sewn together along three edges. In alternative embodiments of the expandable container of the present invention, the two pieces of a polymeric composition 100 according to the present invention having about the same length and width are each sewn to an intermediate material, for instance a rectangular strip of leather. Typically, the length of the rectangular strip of leather is about the distance along three sides of the polymeric composition 100 used to make the expandable container.

In yet a further embodiment, it is envisioned that an additional piece of material is secured to one of the two pieces of polymeric composition 100 in such a position that the material can be used to cover the opening of the expandable container. In such embodiments, the piece of polymeric composition 100 that the material is not secured to has a means of temporarily being attached to the material to close the opening of the expandable container. For instance, the material and the second polymeric composition may have a button and a button hole; a hook and a loop; a sipper; or a latch.

Moreover, in some embodiments of the expandable container having material for covering the opening of the expandable container, the material that covers the opening is also a piece of polymeric composition 100.

In a still further embodiment of the present invention, a tarp is made of a polymeric material with a crease pattern. In a preferred tarp embodiment of the present invention, the polymeric material with a crease pattern has a component wall thickness of between about 1.5 and 5 mm. It is more preferred that the component wall thickness of the tarp embodiment is between about 2 and 3 mm.

Also in the tarp embodiment, it is preferred that the distance from the trough to the crest of a majority of the waves of the crease pattern is between about 10 and 25 cm. It is further preferred that the distance from the trough to the crest of a majority of the waves of the crease pattern is between about 15 and 20 cm.

In a particularly preferred tarp embodiment of the present invention, there are a plurality of grommets along at least one edge of the polymeric material. It is preferred that each of the grommets is within about 10 cm of an edge of the polymeric material. These grommets may be in the mold when the reaction mixture is added or they may be added to the polymeric material after it has cured. Desirably the diameter of the grommets is between about 5 and 15 mm. It is further desired that the diameter of the grommets is between about 8 and 18 mm. It is further desired that the grommets are along at least two edges of the polymeric material, and it is still further desired that the edges with grommets do not intersect.

FIG. 23 shows a tarp 2300 embodiment of the present invention. Tarp 2300 is suspended by two ropes, 2310 and 2320. The ropes 2310 and 2320 are threaded through a plurality of grommets 2330 along non-intersecting edges 2340 and 2350 of tarp 2300.

FIG. 24 a wall hanging 2400 comprised of a plurality of tile 2420 embodiments of the present invention. Wall hanging 2400 also has a border 2410 surrounding each of the several tiles 2420. The tiles 2420 are secured to border 2410 by any conventional method which might including sewing, adhesives, rivets, etc. Border 2410 also includes a plurality of eyelets 2430 which can be used to mount wall hanging 2400.

While each of the tiles 2420 shown in FIG. 24 is depicted as a square, tiles 2420 can have any two dimensional shape such as circular, elliptical, rectangular, triangular, trapezoidal, pentagonal, hexagonal, etc.

FIG. 25 depicts an alternative wall hanging 2500 comprised of a plurality of tile 2520 embodiments of the present invention. Wall hanging 2500 also has a border 2510 surrounding each of the several tiles 2520. The tiles 2520 are secured to border 2510 by any conventional method which might including sewing, adhesives, rivets, etc. Border 2510 may also have a plurality of eyelets 2530, or other structure, for mounting wall hanging 2500.

Similar to the tiles 2420 shown in FIG. 24, tiles 2520 shown in FIG. 25 is depicted as a square, tiles 2520 can have any two dimensional shape such as circular, elliptical, rectangular, triangular, trapezoidal, pentagonal, hexagonal, etc.

The methods of the present invention are capable of fabricating crease pattern elements, devices and device components from elastomeric materials. Allowing the crease pattern elements to relax, at least partially, results in formation of stretchable structures having curved internal surfaces, for example structures that have a wave-shaped and/or buckled contour profile. This aspect of the present invention includes stretchable structures that have a bent structure, such as internal, and optionally external, surfaces provided in a coiled conformation, in a wrinkled conformation, buckled conformation and/or in a wave-shaped configuration.

Flexible substrates useful in stretchable crease pattern components of the present invention include, but are not limited to, polymer substrates and/or plastic substrates. 

I claim:
 1. A polymeric component comprising: a. A component wall thickness of between about 0.1 and 20 mm; b. Said polymeric component having a Shore durometer A scale value between about 15 and 85; and c. Said polymeric component having a repeating crease pattern.
 2. The molded polymeric component of claim 1 further comprising a monomer selected from the group consisting of: Poly [oxy(methyl-1,2-ethanediyl)], α-hydro-ω-hydroxy, Polypropylene glycol, vinyl chloride, Urethane, Siloxanes, Silicones and combinations thereof.
 3. The molded polymeric component of claim 1 wherein said crease pattern further comprises a pattern based on a flat sheet.
 4. The molded polymeric component of claim 3 wherein said crease pattern is substantially uniform across said component.
 5. The molded polymeric component of claim 3 wherein said crease pattern is substantially non-uniform across said component.
 6. The molded polymeric component of claim 1 wherein said crease pattern further comprises a pattern not based on a flat sheet.
 7. The molded polymeric component of claim 1 wherein a surface of said crease pattern forms an acute angle.
 8. The molded polymeric component of claim 7 wherein a surface of said crease pattern acute angles are less than about 20°.
 9. The molded polymeric component of claim 1 wherein a surface of said crease pattern has a surface curved surface.
 10. The molded polymeric component of claim 1 further comprising substantially no visible air bubbles.
 11. The molded polymeric component of claim 1 further comprising a substantially continuous sheet.
 12. The molded polymeric component of claim 1 further comprising at least two colors.
 13. A process for making a polymeric component comprising: a. Preparing a solution of a polymeric material; b. Injecting said polymeric material solution into a mold, said mold having a crease pattern shape; c. Pressurizing said mold with said injected polymeric material to a pressure of between about 200 and 2300 psig for between about 5 and 30 minutes at a temperature of between about 55 and 440° F.; and thereafter d. Removing said polymeric material from said mold.
 14. A floor mat comprising a molded polymeric component comprising: a. A component thickness of between about 0.1 and 20 mm; b. Said polymeric component having a Shore durometer A scale value between about 15 and 85; and c. Said polymeric component having a repeating crease pattern.
 15. A container comprising a plurality of joined molded polymeric components, each of said molded polymeric components comprising: a. A component thickness of between about 0.1 and 20 mm; b. Said polymeric component having a Shore durometer A scale value between about 15 and 85; and c. Said polymeric component having a repeating crease pattern.
 16. A body part protector comprising a molded polymeric component, said molded polymeric component comprising: a. A component thickness of between about 0.1 and 20 mm; b. Said polymeric component having a Shore durometer A scale value between about 15 and 85; and c. Said polymeric component having a repeating crease pattern.
 17. A wall hanging comprising: a. A plurality of tiles, at least one of said tiles comprising a polymeric component having a repeating crease pattern; and b. A border connected to said tiles. 